Manufacture of transfer-decorated extrusion products



T.S.REESE MANUFACTURE OF TRANSFER-DECORATED EXTRSION PRODUCTS Filed April 19, 1957 5. .E y ENLP m T W NM Awwvr A Am www mM Nov. 28, 1961 MANUFAQTUR F TRANSFER-DECORA'IED EXTRUSEN PRGDUCTS Thomas S. Reese, University Heights, Ohio, assigner to De-Noc Chemical Arts, fue., Cleveland, (Bisio, a corporation of @hie Filed Apr. 19, 1957, Ser. No. 653,838 3 Claims. (Cl. 156-i99) This invention relates to the manufacture of transferdecorated extrusion products.

Transfer decorated `products are ywell known, but heretofore it has not ordinarily been practicable to post-form them. When, in the past, attempts have been made to form transfer decorated products after the transfer has been applied to the base material, and particularly under conditions requiring substantial displacement of portions of the products with respect to other portions as in the well-known vacuum-forming operation, defects such as cracking, Wrinkling, blistering and the like have tended to develop in the decorated surface. The ditiiculties appear to have resided in part in the nature of the transfer applied to the product and in part in the nature of the bond between the transfer and the base material. For example, in some cases, even though undecorated plastic products may be post-formed without difficulty, the same product, subject to the same forming step after decoration with the transfer, has been impossible to form satisfactorily without destroying or at least seriously damaging the appearance of the transfer decoration.

One of the objects of the present invention is to eliminate the disadvantages and defects of the kinds referred to above by providing a novel method of manufacture employing a transfer especially adapted 4to be-mounted on a plastic product that is to be subjected to a postforming operation. Another object is the provision of a transfer decorated plastic product and a method of making lthe transfer decorated product which all together result in a superior product -which can be produced at reasonable cost and at high rates of production.

Other objects are the provision of a transfer that is particularly adapted to -be bonded to a plastic sheet immediately after the sheet is extruded; the provision of a method of bonding a transfer to such a sheet; the provision of a thermoplastic transfer which, if desired, may incorporate a thermosett-ing resin that sets up under the conditions under which the transfer `is bonded to the plastic sheet; and, with particular reference to a transfer of the latter type, the provision of a method of applying the transfer to a plastic sheet involving forming the plastic sheet in such manner that the forming operation is completed before the thermosetting material in the transfer has set.

Other objects, advantages and features of the invention will become apparent from the following description of a preferred form thereof, reference being made to the accompanying drawings. The essential characteristics are summarized in the claims.

ln the drawings:

FlGURE 1 is a schematic representation of a system for applying the transfer to the base, stripping the carrier from the transfer, and vacuum-forming the transfer decorated pro duct;

FIGURE 2. is a section, diagrammatic in nature and much enlarged, through the transfer before its application to the base;

FIGURE 3 is a similar section on l-ine 3 3 of FIG- URE 1 immediately following application of the transfer vto the base; and

lndll Patented Nov. 28, 1961 Ffirse Referring to l.FIGURE 1, extruder dll serves as the source of a continuously extruded sheet li. Preferably, the latter is a thermoplastic synthetic resin of a kind that can be melted and extruded at moderate temperatures; eg., temperatures below about 400 F. Although there are many'such, a typical and preferred synthetic resin suitable for these purposes is a modified polystyrene, reference being had not only to styrene polymers but to polymers of methyl styrene, mixtures of the two polymers, and mixtures of either with other thermoplastic synthetic resins. Representative of the latter are the various vinyl polymers and copolymers, polymers derived from the methyl esters of methacrylic acids, polymers derived from the ethyl esters of methacrylic acid, copolymers of the two, the polyacrylonitriles, and the like.

Assuming sheet ll to be commercial polystyrene at a temperature of 400 F. (at which temperature it is not completely reacted but continues to give off an appreciable amount of monomeric styrene in the form of vapor), it proceeds from the extruder to a pair of opposed pinch rolls i2, where under the localized pressure applied by the pinch rolls lit is combined with a transfer indicated in general at 13 that is continuously unwound from supply roll i4 in sheet form.` rtransfer i3 preferably is of the drystrip-ping type; that is to say, it comprises a backing sheet l5 of paper, fabric or the like that has been so treated, as by Icoating it with a stripping layer, that it can be separated from the transfer film 16 at moderate temperatures; e.g., temperatures up to 275 F., merely by pulling the ltwo apart. Although the use of a softening medium is not excluded, it is not usually necessary if a transfer of the dry-stripping type is used. In FIGURE l, for convenience in illustration, the backing sheet i5 is represented as -a single layer and the transfer iilm i6 is likewise represented as consisting of a single layer. In practice, each is made up of a plurality of laminae, as will appear. ln passing through pinch rolls 12, the transfer film 16 is bonded to polystyrene sheet ll. The elevated temperature of the sheet il, the above-described release of unreacted styrene vapors ywhich tend to soften the face of the transfer in contact with the sheet ll, and the pressure exerted by the pinch rolls all cooperate to bond the transfer film i6 permanently to the sheet il. The backing sheet 1S is continuously stripped from the composite at the Zone of the pinch rolls; the stripped backing sheet proceeds from pinch rolls l2 to a takeup roll i8, Where it is wound for reuse. The sheet 11, with the transfer film 16 bonded thereto, proceeds on through the apparatus, as shown, the composite sheet being ind-icated at 17 in the drawing.

At this time the composite is ready for post-forming. The polystyrene sheet 1l is maintained in workable condition, either from residual heat carried over from extruder l0 or by heat supplied by electric heaters d8. The transfer film 16 is permanently bonded to the sheet l1 with a vfusion zone between them as described hereinafter. As will appear, one side of Ipolystyrene sheet 11 (the lower side where the apparatus is of the type illustrated in FIGURE l) constitutes one of the two exposed faces 'of the final product. The other face of the final product is supplied by transfer film 16.

The post-forming apparatus is illustrated in diagrammatic fashion in FIGURE 1 of the drawing. Although other forms of post-forming apparatus may be used, a suitable apparatus, shown at Ztl, comprises a vacuumforming unit that has just been brought into proximity to composite l?. The unit consists of an underlying platen-like element 2l. and an overlying vacuum box 22 embodyin-g a female mold 23. These may be reversed, if desired, in order to take advantage of the action of gravity. Mold 23 and electric heating elements 24 are disposed in the chamber 2S within vacuum box 22.

Vacuum-forming unit 20 travels with composite 17 in the direction indicated by the arrows. Both are conveyed from left 'to right as seen in FIGURE 1 byY endless chains (not shown). These chains, to which composite 17 is fastened at its lateral edges, keep composite 17 from necking down; i.e. narrowing under the inllue'nce of heat. The post-forming step is carried out by creating a vacuum within the box 22 as the unit travels along. Y l i v Y.A similar Vacuum-forming unit in which a vacuum has already been developed and applied to Vcomposite 17 is indicated at 30. It comprises aV lower platen-like element 31 and an opposing vacuum box 32 having a female mold 33 and heating elements 34 suitably located within chamber 35. ln the drawing, composite 17 is shown as having been pulledupward by the vacuum in chamber 35 to produce the bowed portion 36, where it engages the vlower face of mold 33. Unit 30, like unit 20, travels along with composite i7 from left to right through the apparatus as the forming operation is being carriedrout. Another similar vacuum-forming unit 40, which has already reached the limit of its travel, is shown to the right of unit 30. Unit 50 consists of a platen-'like element 41 and a vacuum box 42, the latter having a 'mold 43 and heating elements 44 inrvacuum chamber 45. At this stage, the element 41 and box i2 are separated to release the composite. By the time composite l? has reached this stage, it has hardened suiliciently so that it is no longer workable. It therefore retains the shape imparted to it bythe mold.

As it continues in its travel from left to right, the

" able, it is still warm from heat carried over from extruder augmented by heat supplied by the resistance heating elements 1S, 24, 34 or 44, as the case may have been. Vllt is, however, suliiciently rigid so that it can be handled without likelihood of serious distortion. In the main, subsequent steps comprise trimming the edges of the product to remove unwanted flash, particularly along those edges not severed by'shear 47, 48. The product may then be packed, stored, shipped or put to use, as, for example, as Ia three-dimensional sign, a plaque or a blister package. The product is usually free of defects such'as cracks, wrinkles, bubbles, etc., this notwithstanding the fact that it incorporates what was originally the relative fragile transfer film 16. i

Referring now to FIGURE 2; i.e., the complete transfer 13, it will be noted that there are tive distinct laminae.

i Kote. The grade (Ctd Litho) preferred for use in the invention has a nominalvweight of 70 lbs., a breaking strength of 1,6 to i8 lbs.. per square inch, a thickness of about 0.0043, and an elongation of about 0.009 to 0.0095" as measured by a `Mullin tester. lt has a clay coating which tends to enhancet-he smoothness of the surface. It need not be sized; if sized, the casein, rosin or other material that is used as the size is introduced intoV the paper stock before the latter is cast against the drum. The finished surface, although glossy, is neither hard nor impervious; on the contrary, it tends to be l absorptive notwithstanding the fact that its gloss reading The backing sheet 15 is made up of a support 60 with a stripping layer 61`thereon. The support 60 preferably is paper of the kind made by casting paper stock against a highly polished chromium-plated metal drum of the kind described in Bradner Patent 1,719,166. Finishing the paper stock on a chromium-plated drum of this kind imparts to the paper a particularly smooth, glossy finish. The paper is not calendered in therusual sense of the term, the smoothness of the iinished surface of the paper being imparted by the chromium-plated drum against which the stock is cast. Not being subjected to extreme compression, the body of the paper is not densiiied.

Paper of' the kind described is available vin various thicknesses in weights varying lfrom 30 lbs. to 70 lbs.

It is sold lby Champion Paper and Fibre. Company,y

Hamilton, Ohio under the registered trademark Krome- Yrllhe following islan example ofy a suitable solution:

- Y Parts by weight Polyethylene High dash naphtha 40 Xylol 20 Total Preferably, the polyethylene has a molecular weight in the range between about 12,000 and 21,000. The solution contains about 30% solids, although it may vary from as little as 5% to as 4much as 50%. It is applied by spraying, spreading, brushing, roll coating or an equivalent operation. The coating is dried in any conventient manner to provide the strippinglayer 61. The thickness of the stripping layer preferably is of the order of 0.0005".

In lieu of polyethylene it is possible to use vinyl chloride polymers or copolymers, vinylidene chloride polymers or copolymers or other materials that will adhere firmly Vto the paper and provide a smooth surface from which the transfer hlm 16 can be separated.

The stripping layer so applied to the glossy face of the paper may be hardened in any convenient way, as, for

example, by running the coated product through a drying tunnel through which a current of heated air is being passed. This step serves to drive ol the solvent. The dry material, although very t-hin and located on the glossy face of the paper, adheres tenaciously enough to the paper so that delamination at moderate temperatures is virtually an impossibility.

The exposed surface of lamina k61 is the surface on which the transfer film 16 isformed and from which it is later separated. Separation or stripping must occur between lamina 61 and the transfer film, specifically lamina 62 of the transfer iilm, rather than between lamina 61 and the paper. There must, however, be enough adherence between lamina 61 and lamina 62 to permit the transfer as a whole to be handled as a unit.

Such adherence can be provided by formulating lamina 62 of suitable material such as, for example, the following composition:

Parts by weight 1/2V cellulose acetate butyrate 100.00

In the above formulation, the plasticizer may be Admex 710, a product of Archer-Daniels-Midland Company described as a polymeric-type epoxidized soya bean oil plasticizer of medium oil length.

Compositions containing polyvinyl acetals may likewise be employed, as indicated by the following formulation based on the use of polyvinyl formal:

Parts by weight The polyvinyl butyral should be of the high viscosity type; i.e., 140 to 200 centipoises (7l/2% solution in methanol at C.).

Another suitable composition is the following:

Parts by weight Polyvinyl butyral 10.00 Butylated melamine-formaldehyde resin 2.00 1/2" nitrocellulose (SS type) 2.00 Butyl acetate 3,00 Butyl alcohol 15.00 Toluol 10.00

Total 42.00

Still another such composition is as follows:

Parts by weight The composition from which lamina 62 is formed almost always contains large amounts of volatile solvents which must be eliminated. This is best done at elevated temperatures, particularly if solvent recovery is contemplated. To that end, a process of hardening may be employed similar to that described above in the case of the composition used to form lamina 6l. If so, the incompletely processed material may be passed in continuous fashion through a drying oven heated to a moderate temperature by a current of Vhot air. After elimination of solvents, the thickness of lamina 62 is preferably between about 0.00075" and 0.0025"; a thickness of about 0.001 isA particularly satisfactory.

Once the transfer film (lamina 62) has hardened, it becomes possible to imprint on it so as to form a decorative layer 63. The latter may or may not take the form of a continuous lamina, for by imprinting reference is had to the production of a continuous or discontinuous design, by means of a plate or roller, with or without the use of ink. If ink is used, the ink must of course be compatible with the materials of which lamina 62 is formed.

6 Such an ink may consist of the following:

Parts by weight Carbon black 10.00 Precipitated calcium carbonate 4.00 Acryloid Resin B73 32.00 Acryloid Resin A-l01 8.00 Methyl ethyl ketone 12.00 Toluol 48.00 Xylol l 30.00

Total 144.00

Solids percent-- 371/2 The resins referred to above are polymerized esters of acrylic acid and alpha methyl acrylic acid, methyl and ethyl esters being present. They are products of The Rohm & Haas Company.

The following is another example of a suitable ink:

Parts by weight Titanium dioxide 18.00 Precipitated calcium carbonate 3.00 Ketone resin 5.00 Polyvinyl butyral 10.00 Dioctyl phthalate 3.50 Butyl alcohol 20.50 'Ethyl alcohol 20.00 Toluol 20.00

Total 100.00

Solids percent-- 39.5

essary, given time to dry, a resinous bonding layer,

lamina 64, is laid down on it. The exposed face of this lamina constitutes t-he exposed face of transfer 13 as first made up and is the face of the transfer that is bonded to polystyrene sheet 11. Preferably bonding layer 64 consists largely of a polyacrylate resin such as Acryloid B73 (Rohm and Haas) dissolved in toluol and xylol, the solids content of the liquid ranging from 25% to 40%. This resin consists of esters of acrylic acid and alpha methyl acrylic acid, the methyl and ethyl esters being present as copolymers. Bonding layer 64 is preferably laid down in such manner that it has a wet thickness of about .020" and a dry thickness of from .005" to .00

An example of -a composition suitable for use in forming lam-ina 64 is the following, which composition may be pigmented if desired:

Lamina 64 as so formulated acts as a bonding medium to secure lthe transfer to polystyrene sheet 11. The union is accomplished as the transfer 13 and sheet 11 pass between the rolls 12. The bonding of layer 64 and sheet a 11 is "facilitated by the free monomeric styrene that is present when the hot polystyrene leaves the extruder. The styrene is an excellent solvent for the acrylic resin and brings about an immediate and satisfactory bond between the sheet 11 and transfer nlm 16 so that the backing sheet 15, consisting of paper 60 and lamina 61, can be separated from the rest of the transfer, preferably immediately after leaving pinch rolls =1'2. Transfer film 16 consists of the `transfer layer (lamina 62), the decorative layer 63, and the surface layer (lamina 64): see FIG- URE 2. What has been referred to as composite 17 is shown to better advantage inV FIGURE 4, from which Y will be seen where and how plastic sheet 11 is united to lamina 64. The two are united in a zone of fusion shown at 65: see FIGURE 3.

With further reference lto transfer iilm 16; i.e., that which remains afterV paper 60 and stripping layer 61 have been stripped lfroth transfer 1-3, it will benoted that decorative layer 63` constitutes an intermediate layer between tlie tiansfer layer (lamina 62') 4and the resinousV bonding layer (lamina 64). If formed by the use of ink,

Y decorative layer 63 may be so designed that the transfer is of either the face-up or the face-down type, as desired. If, for example, decorative layer 62 includes a legend, slogan or a trademark consisting of one or more' words, i-t may be so applied to lamina 62 that it will read correctly when viewed from above as indicated bythe arrow a in FIGURE 4, this being -an example of the face-up type of transfer. Y

n the other hand, decorative layer may, if desired, be lso applied that it will read correctly when viewed from the direction of arrow in FIGURE 4, `this being an exampleY of the transfer of the face-down type. The former is suitable where the product shownin FIGUR 4 is to be mounted-on a wall, a mirror or similar object; Vthe lattenwhere it is to be mounted on the inside of a window for viewing from the outside; in the latter, the plastic sheet -11 should be transparent. In the invention as illustrated in FIGURE 1, what is involved -is the use to transfer of the Iface-up type, the object being to mount the concave side of the product on a wall, mirror or similar surface.V

With further 4reference to the transfer layer (lamina '62) rit should be noted that if the transfer film 16 consists entirely of thermoplastic materials, the product may be allowed -to cool and then may be softened by heat at a later time and further worked. Sometimes this is desirable, :but at other -times it is preferred to incorporate a thermosetting resin in the material from Iwhich ftheY transfer film is made. The fourth formulation `given above for the transfer layer 62 includes a butylated melamineformaldehyde resin along with polyvinyl butyral and nitrocellulose. fer layer is ybonded under heat and pressure to an underlying sheet as described above, the melamine-formaldehyde resin cross links with the polyvinyl butyral; the reaction apparently is catalyzed by breakdown products derived, from the (nitrocellulose under the influence' ofV hold appliances.

Thus the invention provides advantageous transfer- .decorated plastic products, a novel process for making the same, and transfers particularly adapted for use 4in such process. In respect of Iall of them, departures from what has been specifically disclosed herein are possible. A wide variety of changes in the formulations may readily be made by those skilled in the -art to which the inven- ,tion pertains. Other types of paper may be used in place When a transfer containing such a trans- 8 of the cast-coated paper that is used in the preferred em- {bodiment of the invention. In the apparatus, other types of post-forming units may take the place of the vacuum-forming 4units illustrated in the drawings, such, for exampleas male-and-female dies.

It is intended that the patent shall cover, by summarize.- tion in appended claims, all features of patentable novelty residing in the invention.

Whatisclaimed is': Y 1. The method of making a decorated plastic product which includes the steps of extruding a polystyrene sheet at an elevated temperature under' conditions such that free monomeric styrene is present in the sheet as it leaves the extrusion orifice; bringing a decorated transfer lm into contact with the'polystyrene sheet while the sheet is still at an elevated temperature and while free monomeric styrene is still present in `the sheet, the transferV lmhaving on its adjacent face a bonding layer consisting essentially of a polyacrylate resin that is soluble in monomeric styrene; and utilizing the solvent action of the monomeric styrene on the polyacrylate resin of the bonding layer to promote permanent bonding of the transfer film to the styrene sheet.

2. The method of making a decorated plastic product which-comprises the steps of extruding a polystyrene sheet at an elevated Ytemperature under conditions such that free monomeric styrene is present in the sheet asA it leaves the extrusion orifice; bringing a decorated transfer film into contact with the 'polystyrene sheet while the sheet is still at an elevated temperature and While free monomeric styrene is still present in it, such transfer film having on its adjacent face a bonding layer consisting .essentially of a polyacrylate resin that is soluble in monomeric styrene; utilizing the solvent action of the monomeric styrene on the polyacrylate resin of the bonding layer to promotev bonding of the transfer film to the extruded sheet; and subjecting the product to a post-forming operation. Y

3. IThe method` of making a decorated plastic product which comprises the steps of extruding a polystyrene sheet at an elevated temperature under conditions such that free monomeric styrene is present in the sheet as it leaves the extrusion orifice; bringing a decorated transfer nlm into contact with the polystyrene sheet while the sheet is still vat an elevated temperature and while free monomeric styrene is still presentrin it, such transfer film havingon its adjacent face a bonding layer consisting essentially of apolyacrylate resin that is soluble in monomeric styrene; utilizing the solvent actionof the monomeric styrene on the polyacrylate resin `of the bonding layer to promote bonding of the transfer film to -the eX- truded sheet; and, beforeV the product has cooled, subjecting the product to a vacuum-forming operation.

Refercnces'Cited in the file of this patent Arled-ter' Dec. 17, 1957 UNITED STATES PATENT OFFICE CERTIFICATION OF CORRECTION Patent No. 3Ol086l November 28 1961 Thomas SQReese It is hereby certified that error appears in 'bhe above numbered patent requiring correction and that the said Letters Patent should read as corrected below.

In the grant, lines 2 and l2, and in the heading to the printed specification, line 5, name of assignee, for "De-Noe Chemical Arts Inc. each occurrence, read Di-i-Noc Chemical Arts, Inca -;l column 7q line 32, for "to", first, occurrencev read of Signed and sealed this 17th day of April 1962 (SEAL) Attest:

ESTON G. JOHNSON DAVID L. LADD Attesting Officer Commissioner of Patents 

1. THE METHOD OF MAKING A DECORATED PLASTIC PRODUCT WHICH INCLUDES THE STEPS OF EXTRUDING A POLYSTYRENE SHEET AT AN ELEVATED TEMPERATURE UNDER CONDITIONS SUCH THAT FREE MONOMERIC STYRENE IS PRESENT IN THE SHEET AS IT LEAVES THE EXTRUSION ORIFICE, BRINGING A DECORATED TRANSFER FILM INTO CONTACT WITH THE POLYSTYRENE SHEET WHILE THE SHEET IS STILL AT AN ELEVATED TEMPERATURE AND WHILE FREE MONOMERIC STYRENE IS STILL PRESENT IN THE SHEET, THE TRANSFER FILM HAVING ON ITS ADJACENT FACE A BONDING LAYER CONSISTING ESSENTIALLY OF A POLYACRYLATE RESIN THAT IS SOLUBLE IN MONOMERIC STYRENE, AND UTILIZING THE SOLVENT ACTION OF THE MONOMERIC STYRENE ON THE POLYACRYLATE RESIN OF THE BONDING LAYER TO PROMOTE PERMANENT BONDING OF THE TRANSFER FILM TO THE STYRENE SHEET. 